Vehicle seat component and method for making same

ABSTRACT

A vehicle seat component ( 14, 14   a   , 14 ′) and its method for making same with a seating portion ( 20 ) molded from either expanded polyethylene or expanded polypropylene to have a density in the range of 0.3 to 2.8 pounds per cubic foot with a softness to provide seating comfort. A seat support ( 22 ) of the seat component is molded from expanded polypropylene and has a density in the range of 5 to 10 pounds per cubic foot so as to provide structural support. The seating portion ( 14, 14   a ) can be molded from either expanded pellets ( 28 ) or extruded and expanded tubes ( 34 ) of either polyethylene or polypropylene, while the seat support ( 22 ) is molded from expanded polypropylene pellets ( 30 ). The seat component ( 14 ′) may have a cover ( 36 ′) molded to the seating portion ( 20 ), and both the moldings may be sequentially in the same mold ( 44 ).

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] This invention relates to a vehicle seat component and also relates to a method for making the seat component.

[0003] 2. Background Art

[0004] Most current vehicle seats are made with polyurethane foam to provide seating comfort. Such polyurethane foam is not recyclable and thus does not help in preserving our natural resources.

[0005] Patent references noted during an investigation conducted in accordance with the present invention include U.S. Pat. No. 3,823,980 Harnick; U.S. Pat. No. 5,100,204 Makihara et al.; U.S. Pat. No. 5,522,645 Dahlbacka; U.S. Pat. No. 5,533,789 McLarty, III et al.; U.S. Pat. No. 6,027,171 Partington et al.; U.S. Pat. No. 6,234,578 Barton et al.; and U.S. Pat. No. 6,423,388 Bateson et al.

SUMMARY OF THE INVENTION

[0006] One object of the present invention is to provide an improved vehicle seat component.

[0007] In carrying out the above object, the vehicle seat component of the invention includes a seating portion molded from an expanded polymer that is either expanded polyethylene or expanded polypropylene such that the seating portion has a density in the range of 0.3 to 2.8 pounds per cubic foot so as to have softness to provide seating comfort. A seat support of the seat component mounts the seating portion on a vehicle body. The seat support is molded from expanded polypropylene and has a density in the range of 5 to 10 pounds per cubic foot so as to have sufficient rigidity to provide structural support.

[0008] The construction of the seat component not only provides seating comfort in a manner that can be efficiently produced but also provides recyclability since the expanded polyethylene and expanded polypropylene can be recycled unlike prior seats utilizing polyurethane foams.

[0009] In the preferred construction of the seat component, the seating portion and the seat support have a molded interface with each other.

[0010] In one embodiment of the seat component, the seating portion is made from expanded polymeric pellets that are fused to each other during the molding and the seat support is made from expanded polypropylene pellets fused to each other during molding, while another embodiment of the seat component has the seating portion made from extruded polymeric tubes that are expanded and then fused to each other during the molding and has the seat support made from expanded polypropylene pellets fused to each other during molding.

[0011] The seat component also includes a cover to which the softer seating component is molded in one practice of the invention. In addition, the seat component in one embodiment has the seating portion provided with vent passages through which air passes to provide cooling to the seat, and this embodiment further includes a fan mounted by the seat support to supply air to the vent passages of the seating portion. More specifically, the seat support includes a vent opening in which the fan is mounted to supply the air to the vent passages of the seating portion.

[0012] Another object of the present invention is to provide an improved method for making a vehicle seat component.

[0013] In carrying out the immediately preceding object, the method for making a vehicle seat component in accordance with the invention is performed by injecting an expanded polymer of either expanded polyethylene or expanded polypropylene into a mold and heating thereof to providing molding that provides a seating portion having a density in the range of 0.3 to 2.8 pounds per cubic foot so as to have softness to provide seating comfort. Expanded polypropylene is injected into a mold and heated to provide molding that provides a seat support having a density in the range of 5 to 10 pounds per cubic foot so as to have sufficient rigidity to provide structural support. The seating portion and the seat support are secured to each other to provide the vehicle seat component.

[0014] In the preferred practice of the method, the seating portion and the seat support are molded in the same mold so as to have a molded interface that provides the securement thereof to each other.

[0015] In one practice of the method, the seating portion is made from expanded polymeric pellets that are fused to each other during the molding and the seat support is also made from expanded polypropylene pellets fused to each other during the molding.

[0016] In another practice of the method, the seating portion is made from extruded polymeric tubes that are expanded and then fused to each other during the molding and the seat support is made from expanded polypropylene pellets fused to each other during the molding.

[0017] In one practice of the method, a cover is initially inserted into the mold in which the expanded polymer is subsequently injected and heated to provide the seating portion which is molded to the cover, and the expanded polypropylene is subsequently injected into the same mold and heated to provide the seat support which has an interface with the seating portion.

[0018] One practice of the method is performed by molding the seating portion with vent passages for air flow that provides cooling. In this practice, a fan is mounted by the seat support to provide cooling air to the vent passages of the seat portion. Furthermore, the seat support is molded with an opening through which the air flow to the fan for flow to the vent passages of the seating portion.

[0019] The objects, features and advantages of the present invention are readily apparent from the following detailed description of the preferred embodiments when taken in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020]FIG. 1 is a side elevational view of a vehicle seat that includes a seat component constructed in accordance with the present invention.

[0021]FIG. 2 is a perspective view of a portion of one embodiment of the seat component.

[0022]FIG. 3 is a perspective view of a portion of another embodiment of the seat component.

[0023]FIG. 4 is a schematic view that illustrates the manner in which the seat components of FIGS. 1-3 are molded.

[0024]FIG. 5 is a perspective view illustrating another embodiment of a vehicle seat component constructed in accordance with the invention.

[0025]FIG. 6 is a sectional view taken through the vehicle component along the direction of line 6-6 in FIG. 5.

[0026]FIG. 7 is a sectional view of the seat component taken along the direction of line 7-7 in FIG. 6.

[0027]FIG. 8 is a schematic view that illustrates the manner in which the seat component of FIGS. 5-7 is molded.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0028] With reference to FIG. 1 of the drawings, a vehicle seat generally indicated by 10 is mounted on the floor 12 of an associated vehicle body and includes a seat cushion component 14 constructed in accordance with the present invention as well as including a seat back component 16 having a headrest component 18. While the vehicle seat component of this invention is specifically disclosed as a seat cushion 14, it will be appreciated that the invention also has use in other seating components such as with the seat back 16, the headrest 18, an armrest, or other vehicle seat components. Both the seat component and the method for making the component will be described in an integrated manner to facilitate an understanding of all aspects of the invention.

[0029] With continuing reference to FIG. 1, the vehicle seat component 14 includes a seating portion 20 that is molded from an expanded polymer that most preferably is expanded polyethylene, but can also be expanded polypropylene, and the molded seating portion has a density in the range of 0.3 to 2.8 pounds per cubic foot so as to have softness to provide seating comfort. The molded seating portion of expanded polyethylene with its specified density in the range of 0.3 to 2.8 pounds per cubic foot is capable of providing greater softness, although the expanded polypropylene can also function adequately even though the expanded polyethylene is preferred. The seat component 14 also includes a seat support 22 for mounting the seating portion on the associated vehicle body. This seat support 22 is molded from expanded polypropylene and has a density in the range of 5 to 10 pounds per cubic foot so as to have sufficient rigidity to provide structural support. The seat component 14 as described can be totally recycled unlike most commercial vehicle seats which use polyurethane foam that cannot be recycled.

[0030] In the preferred construction of the seat component 14, the seating portion 20 and the seat support 22 have a molded interface 24 with each other in a manner that is provided by the molding apparatus 26 illustrated in FIG. 4 as is hereinafter more fully described.

[0031] With reference to FIG. 2, in one construction the seating portion 20 is made from expanded polymeric pellets 28 that are fused to each other during the molding as is hereinafter more fully described. Furthermore, the seat support 22 is made from expanded polypropylene pellets 30 that are also fused to each other during molding. The fused pellets have engaged surfaces with each other so as to have an appearance of having no voids.

[0032] As illustrated in FIG. 3, another construction of the seat component 14 a has the seating portion 20 made from extruded polymeric tubes that are expanded as identified by 34 and then fused to each other during the molding. Such fused tubes have interior voids that promote softness of the seating portion. Furthermore, this construction of the seat component like the other construction has the seat support 24 made from expanded polypropylene pellets 30 that are fused to each other during the molding.

[0033] With reference to FIG. 1, the vehicle seat cushion component 14 illustrated is most normally also provided with a cover 36 of any conventional seating material. Furthermore, as illustrated in FIGS. 5-7, an alternate embodiment of the seat 10′ has the vehicle seat cushion component 14′ provided with a cover 36′ that is molded to the softer seating portion 20 as is hereinafter described in connection with the molding apparatus 26′ illustrated in FIG. 8.

[0034] As shown in FIGS. 6 and 7, the seating portion 20 of seat 10′ is illustrated as having vent passages 38 through which air passes to provide cooling to the seat. The seat also includes a fan 40 mounted by the seat support 22 to supply air to the vent passages 38 of the seating portion. More specifically, the seat support 22 includes a vent opening 42 in which the fan 40 is mounted to supply the air to the vent passages 38 of the seating portion.

[0035] With reference to FIG. 4, the vehicle seat component 14 is molded within the mold apparatus 26 illustrated by first injecting either pellets or tubes of an expanded polymer of either polyethylene or polypropylene into a mold 44 whose mold portions 46 are shown in a closed position to define a mold cavity 48. This introduction of the expanded polymer is provided into the mold from a source 50 of the expanded polymer through a control valve 52 to mold inlets 54. Steam is introduced from a source 55 through a plurality of inlets 56 to fuse the expanded pellets or expanded tubes to each other and provide the molding of the seating portion with, as previously mentioned, the density in the range of 0.3 to 2.8 pounds per cubic foot so as to have softness to provide seating comfort. As the molding takes place, the steam exits the mold through outlet vents 58 spaced over the surface of the mold cavity 48.

[0036] After the molding of the seating portion 20, pellets of expanded polypropylene are injected from a source 60 under the control of valve 52 through the inlets 56 into the mold and the steam is injected from the source 54 through the inlets 56 to provide the fusing of the expanded polypropylene pellets to each other before the steam then exits the mold through outlet vents 58. The seat support 22 is thus molded as previously described with a density in the range of 5 to 10 pounds per cubic foot so as to have sufficient rigidity to provide structural support.

[0037] It should be appreciated that the seating portion 20 and the seat support 22 can be molded in different molds and then subsequently secured to each other in any suitable manner such as by an adhesive or other type of securement. However, the sequential molding of the seating portion 20 and the seat support 22 within the same mold provides the molded interface 24 of the seating portion to the seat support without requiring any post molding securement processing.

[0038] The molding can be performed as previously described in connection with either the seat component 14 of FIG. 2 or the seat component 14 a in FIG. 3. More specifically, the seating portion 20 can be made from expanded polymeric pellets 28 that are fused to each other during the molding, and the seat support 22 can be made from expanded polypropylene pellets 30 that are molded to each other as illustrated in FIG. 2. Furthermore, the seating portion 20 can be made from extruded and expanded polymeric tubes 34 that are fused to each other during the molding, and the seat support 22 can be made from expanded polypropylene pellets 30 that are fused to each other during the molding as illustrated in FIG. 3.

[0039] With reference to FIGS. 5-8, the method for making the vehicle seat component 14′ with the molded cover 36′ is performed in the same manner as described in FIG. 4 except that the mold apparatus 26′ of FIG. 8 utilized has provision for securing the cover 36′ within the mold cavity 48 before the expanded polymer is introduced into the mold to provide the seating portion. As such, the seating portion 20 is molded to the cover 36′ during the molding provided by the steam heating before the steam exits through the outlet vents 58. Actually, the edges of the seat support 22 are also molded to the cover 36′. Furthermore, the vent passages 38 are provided in the seating portion during the molding in any conventional manner and the vent opening 42 is likewise provided in the seat support 22 in a conventional manner.

[0040] After the molding of the seat component either as in FIG. 4 without a cover or as in FIG. 8 with a cover, the associated mold 44 is opened by relative movement of the mold portions 46 away from each other to permit removal of the molded component for further assembly and eventual use.

[0041] While the preferred practice for carrying out the invention has been described in detail, those familiar with the art to which this invention relates will recognize various alternative ways of carrying out the invention as described by the following claims. 

What is claimed is:
 1. A vehicle seat component comprising: a seating portion molded from an expanded polymer selected from the group consisting of expanded polyethylene and expanded polypropylene with the seating portion having a density in the range of 0.3 to 2.8 pounds per cubic foot so as to have softness to provide seating comfort; and a seat support for mounting the seating portion on a vehicle body, and the seat support being molded from expanded polypropylene and having a density in the range of 5 to 10 pounds per cubic foot so as to have sufficient rigidity to provide structural support.
 2. A vehicle seat component as in claim 1 wherein the seating portion and the seat support have a molded interface with each other.
 3. A vehicle seat component as in claim 1 wherein the seating portion is made from expanded polymeric pellets that are fused to each other during the molding, and wherein the seat support is made from expanded polypropylene pellets also fused to each other during molding.
 4. A vehicle seat component as in claim 1 wherein the seating portion is made from extruded polymeric tubes that are expanded and then fused to each other during the molding, and wherein the seat support is made from expanded polypropylene pellets fused to each other during molding.
 5. A vehicle seat component as in claim 1 further including a cover to which the softer seating portion is molded.
 6. A vehicle seat component as in claim 1 wherein the seating portion has vent passages through which air passes to provide cooling to the seat.
 7. A vehicle seat component as in claim 6 further including a fan mounted by the seat support to supply air to the vent passages of the seating portion.
 8. A vehicle seat component as in claim 7 wherein the seat support includes a vent opening in which the fan is mounted to supply the air to the vent passages of the seating portion.
 9. A vehicle seat component comprising: a seating portion molded from an expanded polymer selected from the group consisting of expanded polyethylene and expanded polypropylene with the seating portion having a density in the range of 0.3 to 2.8 pounds per cubic foot so as to have softness to provide seating comfort; a seat support for mounting the seating portion on a vehicle body, and the seat support being molded from expanded polypropylene and having a density in the range of 5 to 10 pounds per cubic foot so as to have sufficient rigidity to provide structural support; the seat support and the seating portion having a molded interface with each other; and a cover to which the softer seating portion is molded.
 10. A method for making a vehicle seat component comprising: injecting an expanded polymer selected from the group consisting of expanded polyethylene and expanded polypropylene into a mold and heating thereof to provide molding that provides a seating portion having a density in the range of 0.3 to 2.8 pounds per cubic foot so as to have softness to provide seating comfort; injecting expanded polypropylene into a mold and heating thereof to provide molding that provides a seat support having density in the range of 5 to 10 pounds per cubic foot so at to have sufficient rigidity to provide structural support; and securing the seating portion to the seat support.
 11. A method for making a vehicle seat component as in claim 10 wherein the seating portion and the seat support are molded in the same mold so as to have a molded interface that provides the securement thereof to each other.
 12. A method for making a vehicle seat component as in claim 10 wherein the seating portion is made from expanded polymeric pellets that are fused to each other during the molding and wherein the seat support is also made from expanded polypropylene pellets fused to each other during the molding.
 13. A method for making a vehicle seat component as in claim 10 wherein the seating portion is made extruded polymeric tubes that are expanded and fused to each other during the molding and wherein the seat support is made from expanded polypropylene pellets fused to each other during the molding.
 14. A method for making a vehicle seat component as in claim 10 wherein a cover is initially inserted into the mold in which the expanded polymer is subsequently injected into the mold and heated to provide the seating portion which is molded to the cover, and wherein the expanded polypropylene is subsequently injected into the same mold and heated to provide the seat support which has an interface with the seating portion.
 15. A method for making a vehicle seat component as in claim 10 wherein the seating portion is molded with vent passages for air flow that provides cooling.
 16. A method for making a vehicle seat component as in claim 15 wherein a fan is mounted by the seat support to provide cooling air to the vent passages of the seating portion.
 17. A method for making a vehicle seat component as in claim 16 wherein the seat support is molded with an opening through which the air flows to the fan for flow to the vent passages of the seating portion.
 18. A method for making a vehicle seat component comprising: inserting a cover into a mold; injecting an expanded polymer selected from the group consisting of expanded polyethylene and expanded polypropylene into the mold and heating thereof to provide molding that provides a seating portion secured to the cover and having a density in the range of 0.3 to 2.8 pounds per cubic foot so as to have softness to provide seating comfort; and injecting expanded polypropylene into the mold and heating thereof to provide molding that provides a seat support having a molded interface with the seating portion and a density in the range of 5 to 10 pounds per cubic foot so as to have sufficient rigidity to provide structural support. 